JP2023019191A - Reactor structure, converter, and power conversion device - Google Patents

Abstract

To provide a reactor structure which is excellent in productivity.SOLUTION: A reactor structure includes a reactor and a bus bar, wherein the reactor has a pin formed of a resin material, the bus bar includes a plate-like first part which is connected to a winding end of the coil so as to overlap the wiring end, and a plate-like second part extending from the first part, the second part has a first surface, a second surface and a penetration part, the pin has a plurality of shaft parts which is divided in a direction perpendicular to a pin shaft direction and is arranged inside the penetration part, and head parts which are formed at tips of each of the shaft parts and are arranged outside the penetration part, each of the shaft parts faces an inner peripheral surface of the penetration part so as to regulate movement of the bus bar in a direction perpendicular to the pin shaft direction, and each of the head parts faces the second surface so as to regulate movement of the bus bar in the pin shaft direction.SELECTED DRAWING: Figure 3

Description

The present disclosure relates to reactor structures, converters, and power converters.

A reactor structure is a component of a converter provided in a hybrid vehicle or the like. For example, a reactor structure disclosed in Patent Literature 1 includes a reactor and terminal members. A reactor includes a coil and a core. A coil is formed by spirally winding a wire. The reactor described in Patent Document 1 further includes a frame-shaped bobbin, an inner bobbin, and a case. The frame-shaped bobbin and the inner bobbin are insulating members that ensure insulation between the coil and the core. The case houses the assembly of the coil, core and insulating member.

A terminal member provided in the reactor structure is also called a busbar. The busbar electrically connects the coil and the external device. The ends of the busbar are connected to the ends of the coil by welding or the like. The intermediate portion of the bus bar described in Patent Document 1 is screwed to a case that constitutes the reactor. By screwing the busbar to the case, the position of the busbar with respect to the reactor is determined, thereby facilitating the connection between the end of the busbar and the end of the coil.

Japanese Patent Application Laid-Open No. 2014-130949

In the reactor structure of Patent Literature 1, it takes time and effort to screw the bus bar. Moreover, the number of parts constituting the reactor structure increases. Therefore, the productivity of the reactor structure of Patent Document 1 is not good.

Accordingly, one object of the present disclosure is to provide a reactor structure with excellent productivity. Another object of the present disclosure is to provide a converter and a power conversion device with excellent productivity.

The reactor structure of the present disclosure is
a reactor having a coil and a core;
a bus bar for electrically connecting the coil and an external device,
The reactor is
having a pin made of a resin material,
The busbar is
a plate-shaped first portion connected to the winding end portion of the coil in an overlapping state;
A plate-shaped second portion extending from the first portion,
The second part is
a first surface facing the reactor;
a second surface opposite the first surface;
a penetrating portion penetrating from the first surface to the second surface;
The pin is
a plurality of shaft portions divided in a direction orthogonal to the axial direction of the pin and arranged inside the through portion;
a head formed at the tip of each shaft and arranged outside the penetrating portion;
each shaft faces the inner peripheral surface of the through portion so as to restrict movement of the bus bar in a direction perpendicular to the axial direction of the pin;
Each head faces the second surface so as to restrict movement of the busbar in the axial direction of the pin.

The converter of the present disclosure is
A reactor structure of the present disclosure is provided.

The power conversion device of the present disclosure is
A converter of the present disclosure is provided.

The reactor structure of the present disclosure, the converter of the present disclosure, and the power converter of the present disclosure are excellent in productivity.

FIG. 1 is a schematic perspective view of a reactor structure described in Embodiment 1. FIG. FIG. 2 is a schematic perspective view of a set of reactors described in Embodiment 1. FIG. 3 is a partially enlarged view of the vicinity of the bus bar in the reactor described in Embodiment 1. FIG. 4 is a partially enlarged view of the vicinity of pins in the reactor described in Embodiment 1. FIG. 5 is a schematic perspective view of the busbar described in Embodiment 1. FIG. 6A and 6B are schematic explanatory diagrams for explaining the shapes of the pin and the penetrating portion described in Embodiment 1. FIG. 7 is a cross-sectional view taken along line VII-VII of FIG. 3. FIG. FIG. 8 is a schematic perspective view of a busbar described in Embodiment 3. FIG. 9 is a schematic perspective view of a busbar described in Embodiment 4. FIG. FIG. 10 is a configuration diagram schematically showing the power supply system of the hybrid vehicle described in Embodiment 5. As shown in FIG. FIG. 11 is a circuit diagram showing an outline of an example of a power converter including the converter described in Embodiment 5. FIG.

[Description of Embodiments of the Present Disclosure]
First, the embodiments of the present disclosure are listed and described.

<1> The reactor structure according to the embodiment is
a reactor having a coil and a core;
a bus bar for electrically connecting the coil and an external device,
The reactor is
having a pin made of a resin material,
The busbar is
a plate-shaped first portion connected to the winding end portion of the coil in an overlapping state;
A plate-shaped second portion extending from the first portion,
The second part is
a first surface facing the reactor;
a second surface opposite the first surface;
a penetrating portion penetrating from the first surface to the second surface;
The pin is
a plurality of shaft portions divided in a direction orthogonal to the axial direction of the pin and arranged inside the through portion;
a head formed at the tip of each shaft and arranged outside the penetrating portion;
each shaft faces the inner peripheral surface of the through portion so as to restrict movement of the bus bar in a direction perpendicular to the axial direction of the pin;
Each head faces the second surface so as to restrict movement of the busbar in the axial direction of the pin.

In the above-described reactor structure, the plurality of shaft portions that constitute the pins act as stops against the inner peripheral surface of the through portion, thereby restricting movement of the bus bar in a direction perpendicular to the axial direction of the pins. Further, each head portion of the pin serves as a stop against the second surface of the busbar, restricting movement of the busbar in the axial direction of the pin. In this way, the three-dimensional position of the busbar relative to the reactor is determined by the pins of the reactor only by fitting the pins of the reactor into the through-holes of the busbar. Such a reactor structure does not require screws for fixing the busbar to the reactor. In addition, since the three-dimensional movement of the busbar is restricted, it is easy to weld the first portion of the busbar and the winding ends. Therefore, the reactor structure has excellent productivity.

In the reactor structure in which the three-dimensional movement of the busbar with respect to the reactor is sufficiently restricted, even if the reactor vibrates, excessive stress is less likely to act on the weld between the first portion of the busbar and the winding end.

<2> As one form of the reactor structure according to the embodiment,
The second portion includes a notch-shaped guide portion connected to the through portion,
The plurality of shaft portions may be two shaft portions divided in the width direction of the guide portion.

The width direction of the guide portion is a direction orthogonal to the axial direction of the through portion and the extending direction of the guide portion. In the configuration of form <2>, the bus bar can be slid in the extension direction of the guide portion and attached to the reactor. In this case, even if the head of the pin is large, the pin can be arranged in the through portion. If the head is large, it becomes difficult to remove the busbar in the axial direction of the pin.

<3> As one form of the reactor structure according to the above form <2>,
The width of the portion of the guide portion connected to the through portion may be narrower than the maximum length of the opening of the through portion in the width direction of the guide portion.

In the configuration of form <3>, the pin is likely to get caught in the portion of the penetrating portion that is connected to the guide portion. Therefore, the bus bar is less likely to come off in the direction opposite to the sliding direction at the time of attachment.

<4> As one form of the reactor structure according to the above form <2> or the above form <3>,
The width of the guide portion may be widened with increasing distance from the through portion.

In the configuration of form <4>, when the busbar is attached to the reactor, the pin is smoothly guided by the guide portion. Therefore, it is easy to attach the busbar to the reactor.

<5> As one form of the reactor structure according to the embodiment,
The penetrating part may be provided at a position closer to the first part in the second part.

In the configuration of form <5>, the position where the bus bar is held by the pin is close to the first portion side, so that the position of the first portion is stabilized. In the configuration of form <5>, it is easy to align the first portion and the winding end portion, so that connection between the first portion of the busbar and the winding end portion of the coil is facilitated.

<6> As one form of the reactor structure according to the embodiment,
an X direction in which the winding end portion and the first portion are arranged in parallel;
a Y direction that intersects the X direction and is along the extending direction of the winding ends;
The axial direction of the pin may be along the Y direction.

In the configuration of form <6>, the movement of the busbar in the X direction and the Z direction is restricted by the shaft portion of the pin. The Z direction is a direction crossing the X direction and the Y direction. Moreover, the movement of the busbar in the Y direction is restricted by the head of the pin. Therefore, in the configuration of form <6>, the three-dimensional movement of the bus bar is restricted by the pin.

<7> As one form of the reactor structure according to the embodiment,
The reactor includes an insulating member that determines the relative position of the coil and the core,
The pin may be provided on the insulating member.

In the configuration of form <7>, the insulating member holds the coil and the core in a positioned state. Further, in the configuration of form <7>, since the pin is formed of a part of the insulating member, insulation between the bus bar and the core is ensured. Here, examples of the insulating member that determines the relative position of the coil and the core include a holding member arranged between the end of the coil and the core. Moreover, as the insulating member, there is a resin molded member that integrates the coil and the core.

<8> As a reactor structure according to the above aspect <7>,
The insulating member may be a resin molded member that integrates the coil and the core.

The resin mold member makes it difficult to disassemble the coil and the core. Therefore, the assembly of the coil and core becomes easy to handle. Since the pin is integrated with the resin molded member, the productivity of the reactor is improved.

<9> The converter according to the embodiment,
The reactor structure according to any one of the above forms <1> to <8> is provided.

The converter includes the reactor structure of the embodiment with excellent productivity. Therefore, the converter is excellent in productivity.

<10> The power conversion device according to the embodiment,
The converter of form <9> is provided.

The power conversion device includes the converter of the embodiment with excellent productivity. Therefore, the power converter is excellent in productivity.

[Details of the embodiment of the present disclosure]
Hereinafter, embodiments of a reactor structure, a converter, and a power converter according to the present disclosure will be described based on the drawings. The same reference numerals in the drawings indicate the same names. The present invention is not limited to the configurations shown in the embodiments, but is indicated by the scope of claims, and is intended to include all modifications within the scope and meaning equivalent to the scope of claims.

<Embodiment 1>
In Embodiment 1, the configuration of the reactor structure α will be described based on FIGS. 1 to 7. FIG. A reactor structure α shown in FIG. 1 includes a reactor 1 having a coil 2 and a core 3 (FIG. 2), and a busbar 4 electrically connecting the coil 2 to an external device. One of the features of this reactor structure α is that the reactor 1 has a pin 5 . The pin 5 positions the busbar 4 with respect to the reactor 1 by restricting the movement of the busbar 4 . Each configuration provided in the reactor structure α will be described in detail below.

≪Reactor≫
The reactor 1 of this example includes a braid 10 ( FIG. 2 ) and an insulating member 9 . The braid 10 is a combination of the coil 2 and the core 3, as shown in FIG. The insulating member 9 is a member attached to the braid 10 to constitute the reactor 1 or a member attached to the reactor 1 . The insulating member 9 is arranged outside the coil 2 . The insulating member 9 of this example determines the relative positions of the coil 2 and the core 3 . The insulating member 9 may not have the function of determining the relative positions of the coil 2 and the core 3 . The insulating member 9 is made of a resin material. The pin 5 is provided on the insulating member 9 and protrudes from the insulating member 9 .

[coil]
The coil 2 of this example includes a winding portion 20 formed by spirally winding a wire. A known winding can be used for the winding. The winding wire of this example is a coated rectangular wire having a conductor wire and an insulating coating. The conductor wire is composed of a rectangular wire made of copper. The insulating coating is made of enamel. The wound portion 20 is formed of an edgewise coil obtained by edgewise winding a coated rectangular wire. The coil 2 used in this example includes one winding portion 20 . Unlike this example, the coil 2 may have a plurality of windings 20 . For example, a coil 2 with two windings 20 arranged in parallel can be mentioned.

The shape of the winding portion 20 is a rectangular tube. Rectangles include squares. That is, the end face shape of the winding portion 20 is a rectangular frame shape. Since the shape of the winding portion 20 is a rectangular tube, the contact area between the winding portion 20 and the installation target tends to be larger than when the winding portion is cylindrical with the same cross-sectional area. As a result, the heat of the reactor structure α is easily radiated to the installation target via the winding portion 20 . Furthermore, the stability of the winding portion 20 with respect to the installation target is improved. The corners of the winding portion 20 are preferably rounded. In this example, the lower surface of the reactor 1 in FIGS. 1 and 2 is the surface to be installed.

Winding end portions 21 and 22 of the coil 2 are drawn out to the outer peripheral side of the winding portion 20, respectively. The insulating coating is peeled off from the winding end portions 21 and the winding end portions 22 to expose the conductor wires. A bus bar 4 is connected to the exposed conductor line. In the drawing of this example, only the bus bar 4 attached to the winding end portion 21 is illustrated. The configuration of the busbars attached to the winding end portions 22 may be the same as or different from that of the busbars 4 illustrated. An external device is connected to the coil 2 via a busbar 4 . Illustration of external equipment is omitted. The external device includes a power supply for supplying power to the coil 2 and the like.

Here, the direction in the reactor structure α is defined with reference to the coil 2 and the bus bar 4 . First, the direction in which the winding end portion 21 of the coil 2 and the first portion 41 of the busbar 4 are arranged in parallel is defined as the X direction. The first portion 41 is a portion of the bus bar 4 that is connected to the winding end portion 21 in an overlapping state. A detailed configuration of the first portion 41 will be described later. A direction intersecting with the X direction and along the extending direction of the winding end portion 21 is defined as a Y direction. In this example, the Y direction is orthogonal to the X direction. A direction intersecting both the X direction and the Y direction is defined as the Z direction. In this example, the Z direction is orthogonal to the X and Y directions. Furthermore, the following directions are defined.
・X1 direction: the direction toward the winding end portion 21 when viewed from the busbar 4 among the X directions ・X2 direction: the direction opposite to the X1 direction ・Y1 direction: the direction toward the tip of the winding end portion 21 among the Y directions・Y2 direction: the opposite direction to the Y1 direction ・Z1 direction: the direction away from the installation target of the reactor 1 among the Z directions ・Z2 direction: the opposite direction to the Z1 direction

[core]
The core 3 is a magnetic body in which a closed magnetic circuit is formed. The core 3 is a compact or composite compact. The powder compact is obtained by pressure-molding raw material powder containing soft magnetic powder. Soft magnetic powders include pure iron and iron alloys. The molded composite material is obtained by filling a mold with a mixture of soft magnetic powder and unsolidified resin and solidifying the resin. Soft magnetic powder is dispersed in a resin in the molded body of the composite material. The core 3 is configured by combining a core piece made of a powder compact and a core piece made of a composite material, or by covering the core piece made of a compact with a composite material. You can

The core 3 has an inner core portion 31 and an outer core portion 32 . The inner core portion 31 is arranged inside the winding portion 20 of the coil 2 and has a portion along the axial direction of the winding portion 20 . In this example, both ends of the portion of the core 3 along the axial direction of the winding portion 20 protrude from the end surface of the winding portion 20 . The projecting portion is also part of the inner core portion 31 .

The shape of the inner core portion 31 is not particularly limited as long as it conforms to the internal shape of the winding portion 20 . The inner core portion 31 of this example has a substantially rectangular parallelepiped shape. The inner core portion 31 may be configured by connecting a plurality of split cores and a gap plate, or may be a single member.

The outer core portion 32 is a portion of the core 3 that is arranged outside the winding portion 20 . The shape of the outer core portion 32 is not particularly limited as long as it is a shape that connects the ends of the inner core portion 31 . The outer core portion 32 of this example includes an end core piece facing the Y1-direction end surface of the winding portion 20, an end core piece facing the Y2-direction end surface of the winding portion 20, and an X1-direction side surface of the winding portion 20. A side core piece and a side core piece facing the side surface of the winding portion 20 in the X2 direction are provided. Therefore, the outer core portion 32 of this example has a rectangular annular shape when viewed from the Z direction.

The core 3 of this example is composed of two split cores 3A and 3B. The split core 3A has a substantially "T" shape when viewed from the Z direction. The split core 3B has a substantially "E" shape when viewed from the Z direction. The shape of split cores 3A and 3B is not particularly limited. For example, a combination of a substantially “I”-shaped split core serving as the inner core portion 31 and a substantially “O”-shaped split core serving as the outer core portion 32 may be used. The core 3 may be composed of three or more split cores. For example, a combination of a substantially “I”-shaped split core serving as the inner core portion 31 and two substantially “U”-shaped split cores serving as the outer core portion 32 may be used.

[Insulating material]
The insulating member 9 of this example is a resin molded member 6 that integrates the coil 2 and the core 3 as shown in FIG. The resin molded member 6 also has a function of protecting the coil 2 and the core 3 from the external environment.

The resin molded member 6 may cover the entire braid 10 or may cover only a part of the braid 10 (see FIG. 2). The resin molded member 6 of this example does not cover the outer surface of the wound portion 20 in the Z direction. That is, the Z-direction outer surface of the wound portion 20 is exposed from the resin mold member 6 . As a result, the heat generated by the coil 2 is easily released to the outside.

The resin mold member 6 is made of, for example, polyphenylene sulfide (PPS) resin, polytetrafluoroethylene (PTFE) resin, liquid crystal polymer (LCP), polyamide (PA) resin, polybutylene terephthalate (PBT) resin, acrylonitrile-butadiene-styrene ( It is made of a thermoplastic resin such as ABS) resin. In addition, the resin mold member 6 may be made of a thermosetting resin such as unsaturated polyester resin, epoxy resin, urethane resin, silicone resin, or the like. By containing a ceramic filler in these resins, the heat dissipation of the resin molded member 6 is improved. Ceramic fillers include, for example, non-magnetic powders such as alumina and silica.

The resin molded member 6 of this example includes a pedestal portion 60, a terminal block 61, and pins 5, as shown in FIG. The pedestal portion 60 , the terminal block 61 and the pins 5 are integrally formed on the resin mold member 6 with the resin forming the resin mold member 6 . Each configuration provided in the resin molded member 6 will be described below.

Pedestal Part The pedestal part 60 is a pedestal for supporting the second portion 42 of the busbar 4 . The pedestal portion 60 is provided on the first surface 6 a of the resin mold member 6 . The first surface 6a is a surface in the vicinity of the winding end portion 21 facing in the Z1 direction. A portion of the resin mold member 6 including the first surface 6a covers the upper surface of the outer core portion 32 located on the Y1 direction side in FIG. That is, the pedestal portion 60 is positioned above the outer core portion 32 . The pedestal portion 60 protrudes in the Z1 direction from the first surface 6a, as shown in FIG. A surface of the pedestal 60 facing the Z1 direction is parallel to the XY plane. The pedestal portion 60 is in surface contact with the second portion 42 of the busbar 4 shown in FIG. The base portion 60 stabilizes the fixed state of the busbar 4 and secures an insulating distance between the busbar 4 and the core 3 (FIG. 2). Here, the pedestal portion 60 is not essential. Without the pedestal 60, the second portion 42 of the busbar 4 is in surface contact with the first surface 6a.

Terminal Block The terminal block 61 is a pedestal for supporting connection terminals of an external device (not shown). The connection terminals of this example are superimposed on the surface of the bus bar 4 facing the Z1 direction and screwed. The terminal block 61 is provided with screw holes 61h into which screws for fixing connection terminals are attached. The screw hole 61h of this example extends in the Z direction. In this example, a nut is embedded in the terminal block 61 . The inner peripheral surface of this nut constitutes a screw hole 61h. The axis of this screw hole 61h coincides with the axis of a terminal hole 42h of the bus bar 4, which will be described later. Therefore, by screwing the connection terminal, the connection terminal is fixed to the terminal block 61 and electrically connected to the bus bar 4 . Here, a nut is not essential. Also, the axis of the screw hole 61h may extend in a direction crossing the Z direction.

- Pin The pin 5 is a protrusion protruding from the resin molded member 6 . The pin 5 is a member that determines the three-dimensional position of the busbar 4 with respect to the reactor 1 by being fitted into a through portion 45 of the busbar 4 to be described later. The pin 5 is also a member that suppresses vibration of the busbar 4 with respect to the reactor 1 . The axial direction of the pin 5 in this example coincides with the Y direction. The pin 5 of this example is provided on the second surface 6 b of the resin molded member 6 . The second surface 6b is a surface connected to the end of the first surface 6a in the Y1 direction, and is a surface in the vicinity of the winding end 21 facing the Y1 direction. Accordingly, the pin 5 extends in the Y1 direction.

As shown in FIG. 4, the pin 5 has a plurality of shafts 51,52. The plurality of shaft portions 51 and 52 are arranged with a space therebetween. The number of shaft portions 51 and 52 in this example is two. The number of shaft portions 51 and 52 may be three or more. Heads 55 and 56 are provided at the tips of the shafts 51 and 52, respectively. The shaft portions 51 and 52 are fitted into the through portion 45 (see FIG. 3). The heads 55 and 56 are arranged outside the through portion 45 (see FIG. 3), that is, on the Y1 direction side of the bus bar 4 . Different from this example, the pin 5 may be configured to include one base protruding from the resin molded member 6 and a plurality of shafts protruding from the base. A plurality of shafts protruding from the base are spaced apart from each other. The distal end portions of the plurality of shaft portions are elastically deformable so as to approach each other.

The shape of the pin 5 of this example will be described with reference to FIG. FIG. 6 only shows part of the busbar 4 and the pins 5 . FIG. 6 shows the state before the pin 5 is fitted into the through portion 45 of the busbar 4 . As for the shape of the pin 5, FIG. 4 may be referred to as appropriate. The arrangement state of the pins 5 in the penetrating portion 45 will be described when the busbar 4 is described.

The shaft portion 51 of the pin 5 has an outer peripheral surface 510 and an inner peripheral surface 511 . The outer peripheral surface 510 faces the inner peripheral surface 450 of the through portion 45 when the shaft portion 51 is fitted into the through portion 45 . The inner peripheral surface 511 is a surface facing the shaft portion 52 . Shaft portion 52 also has an outer peripheral surface 520 and an inner peripheral surface 521 . The outer peripheral surface 520 faces the inner peripheral surface 450 of the through portion 45 when the shaft portion 52 is fitted into the through portion 45 . The inner peripheral surface 521 is a surface facing the inner peripheral surface 511 . The outline of the pin 5 connecting the outer peripheral surface 510 of the shaft portion 51 and the outer peripheral surface 520 of the shaft portion 52 when viewed in the Y direction follows the shape of the inner peripheral surface 450 of the through portion 45 . A predetermined space is provided between the inner peripheral surface 511 of the shaft portion 51 and the inner peripheral surface 521 of the shaft portion 52 . Therefore, when an external force acts on the shaft portion 51 and the shaft portion 52 in the direction of approaching each other, the shaft portion 51 and the shaft portion 52 can be elastically deformed in the direction of approaching each other. When the external force is removed, the shaft portions 51 and 52 return to the state before elastic deformation. The interval is, for example, 1 mm or more and 5 mm or less. The distance may be 2 mm or more and 4 mm or less, or 2.5 mm or more and 3.5 mm or less. The distance between the shaft portions 51 and 52 in the axial direction, ie, the Y direction, may vary.

The cross-sectional area of the shaft portion 51 may be uniform in the axial direction of the shaft portion 51 or may be different. Similarly, the cross-sectional area of the shaft portion 52 may be uniform in the axial direction of the shaft portion 52 or may be different. Here, the cross-sectional area is the area of a cross section obtained by cutting the shaft portions 51 and 52 along a plane perpendicular to the axial direction of the shaft portions 51 and 52 .

The head portion 55 provided on the shaft portion 51 protrudes outside the outer peripheral surface 510 of the shaft portion 51 , that is, on the side away from the shaft portion 52 . A surface of the head portion 55 facing the head portion 56 is flush with the inner peripheral surface 511 of the shaft portion 51 . The head portion 56 provided on the shaft portion 52 protrudes outside the outer peripheral surface 520 of the shaft portion 52 , that is, on the side away from the shaft portion 51 . A surface of the head portion 56 facing the head portion 55 is flush with the inner peripheral surface 521 of the shaft portion 52 .

[others]
Reactor 1 may include a holding member (not shown) that holds coil 2 and core 3 shown in FIG. The holding member is interposed between the end surface of the winding portion 20 and the outer core portion 32 and has a function of ensuring insulation between the coil 2 and the core 3 . The holding member is made of an insulating material that can be used to manufacture the resin molded member 6 . That is, the holding member is the insulating member 9 that determines the relative positions of the coil 2 and the core 3 . If the reactor 1 has a holding member, the resin molded member 6 may be omitted. In that case, the pin 5 is preferably provided on the holding member. Alternatively, the pin 5 may be provided on a core mold member that molds the outer core portion 32 . A core mold member is a kind of insulating member 9 . The core mold member may or may not have the function of determining the relative positions of the coil 2 and the core 3 .

≪Bus bar≫
The busbar 4 is a member that electrically connects the coil 2 and an external device, as shown in FIG. Therefore, the bus bar 4 is made of metal with excellent conductivity. Such metals include copper, copper alloys, aluminum, aluminum alloys, and the like. The busbar 4 includes a first portion 41 and a second portion 42, as shown in FIGS.

The first portion 41 is a portion that is connected to the winding end portion 21 of the coil 2 in an overlapping state. The first portion 41 of this example has a rectangular plate shape. The thickness direction of the rectangular plate-shaped first portion 41 coincides with the X direction. Further, the thickness direction of the winding end portion 21 made of a rectangular wire also coincides with the X direction. Therefore, the surface of the first portion 41 facing in the X1 direction and the surface of the winding end portion 21 facing in the X2 direction are in surface contact. The first portion 41 and the winding end portion 21 are connected by welding, pressure welding, or the like. Welding includes TIG welding and the like. Friction stir welding etc. are mentioned as pressure welding. In addition, the first portion 41 and the winding end portion 21 may be connected by an annular fastener or the like that tightens the first portion 41 and the winding end portion 21 from the outer periphery.

The second portion 42 is a plate-like piece of the busbar 4 excluding the first portion 41 . The plate-like second portion 42 has a first surface 4a, a second surface 4b and a third surface 4c. The first surface 4 a is a surface facing the reactor 1 . The second surface 4b is the surface opposite to the first surface 4a. In the case of this example, the surface that can be confirmed from the outside of the reactor structure α in FIG. 3 is the second surface 4b. The third surface 4c is a surface that connects the first surface 4a and the second surface 4b, that is, an edge surface of the second portion 42, as shown in FIG.

The second portion 42 includes a connecting portion 421 , an intermediate portion 422 , a terminal portion 423 and a fixing portion 424 . The connecting portion 421 is a portion connected to the end portion of the first portion 41 in the Z2 direction. The connecting portion 421 is curved in the X2 direction from the Z2-direction end of the first portion 41 . A notch 425 is provided in the vicinity of the connecting portion 421 in the first portion 41 . Due to the notch 425 , a curved connecting portion 421 is likely to be formed when the bus bar 4 is manufactured by bending the plate material.

The intermediate portion 422 is a plate-like piece parallel to the XY plane. Therefore, the thickness direction of the intermediate portion 422 coincides with the Z direction and is orthogonal to the thickness direction of the first portion 41 . The intermediate portion 422 of this example extends in the X2 direction from the connecting portion 421, bends in the Y2 direction, and further extends in the X2 direction. The intermediate portion 422 is a portion that becomes the main conductive path of the busbar 4 . The thickness of the intermediate portion 422 is substantially uniform in the extending direction of the intermediate portion 422 . The width of the intermediate portion 422 is also substantially uniform in the extending direction of the intermediate portion 422 . Accordingly, the conductor cross-sectional area of the intermediate portion 422 is substantially the same along the extending direction of the intermediate portion 422 .

The terminal portion 423 is connected to the end portion of the intermediate portion 422 in the X2 direction. 3 and 5, the boundary between the intermediate portion 422 and the terminal portion 423 is indicated by a chain double-dashed line. The terminal portion 423 is a plate-like piece parallel to the XY direction. The terminal portion 423 extends from the end portion of the intermediate portion 422 in a direction between the X2 direction and the Y1 direction. The terminal portion 423 is provided with a terminal hole 42h. 42 h of terminal holes are opened in the 1st surface 4a and the 2nd surface 4b in the terminal part 423. As shown in FIG.

The fixed portion 424 is connected to an intermediate portion in the X2 direction of the end surface of the intermediate portion 422 in the Y1 direction. 3 and 5, the boundary between the intermediate portion 422 and the fixed portion 424 is indicated by a chain double-dashed line. The fixed portion 424 extends in the Z2 direction after being bent in the Z2 direction. Therefore, the thickness direction of the portion of the fixed portion 424 extending in the Z2 direction is aligned with the Y direction. As shown in FIG. 5, the through portion 45 and the guide portion 46 are provided on the lower end side of the fixing portion 424, that is, on the end portion side in the Z2 direction.

[Penetration part]
The through portion 45 penetrates through the fixed portion 424 in the thickness direction. That is, the penetrating portion 45 opens to the first surface 4 a and the second surface 4 b of the fixed portion 424 . In other words, the axial direction of the through hole 45 matches the plate thickness direction of the fixed portion 424 . The contour shape of the opening of the penetrating portion 45 is not particularly limited. As shown in FIG. 6, the contour shape of the opening of the penetrating portion 45 of this example is a quadrangle with rounded corners, with one side missing. Unlike this example, the contour shape of the opening of the through portion 45 may be an ellipse or a perfect circle with a part missing.

The shaft portions 51 and 52 of the pin are fitted into the through portion 45 . The outer peripheral surface 510 of the shaft portion 51 and the outer peripheral surface 520 of the shaft portion 52 are in contact with or close to the inner peripheral surface 450 of the through portion 45 . Proximity in this specification means that the gap between the outer peripheral surfaces of the shaft portions 51 and 52 and the inner peripheral surface 450 of the penetrating portion 45 is 1 mm or less. The gap may be, for example, 0.7 mm or less, or 0.5 mm or less. The gap is preferably as small as possible in terms of manufacturing.

The shafts 51 and 52 contacting or adjoining the inner peripheral surface 450 of the penetrating portion 45 abut against the inner peripheral surface of the penetrating portion 45 to restrict the movement of the bus bar 4 in the direction orthogonal to the axial direction of the pin 5. . In this example, the shafts 51 and 52 restrict the movement of the busbar 4 in the direction along the XZ plane.

The heads 55 and 56 of the pin 5 have projecting portions 55P and 56P projecting outside the outer peripheral surfaces 510 and 520 of the shaft portions 51 and 52, respectively, as shown in FIG. The projecting portions 55P and 56P overlap the second surface 4b when the fixing portion 424 is viewed from the second surface 4b side. The surfaces of the projecting portions 55P and 56P on the busbar 4 side are in contact with or close to the second surface 4b of the busbar 4 . Proximity in this example means that the gap between the surface of the protruding portions 55P and 56P on the side of the bus bar 4 and the second surface 4b is 1 mm or less. The gap may be, for example, 0.7 mm or less, or 0.5 mm or less. The gap is preferably as small as possible in terms of manufacturing.

Heads 55 , 56 contacting or close to second surface 4 b abut and stop second surface 4 b to restrict movement of bus bar 4 in the axial direction of pin 5 . In this example, the heads 55 and 56 restrict the busbar 4 from moving in the Y direction.

Here, in the busbar 4 shown in FIG. 5 , the through portion 45 is preferably provided at a position in the second portion 42 closer to the first portion 41 side. In the configuration including the fixing portion 424 as in this example, it is preferable that the fixing portion 424 is provided at a position closer to the first portion 41 side. A position closer to the first portion 41 side means a position closer to the first portion 41 side than the intermediate position of the second portion 42 . The intermediate position of the second portion 42 is a position that bisects the length of the second portion 42 along the X direction. When the penetrating portion 45 is closer to the first portion 41 side, the position where the bus bar 4 is held by the pin 5 is closer to the first portion 41 side. As a result, the position of the first portion 41 is stabilized.

[Guide part]
As shown in FIG. 6 , the guide portion 46 is a notch leading to the through portion 45 . The extending direction of the guide portion 46 of this example matches the Z direction. Therefore, two inner peripheral surfaces 460 of the guide portion 46 face each other in the X direction. In other words, the space sandwiched between the two inner peripheral surfaces 460 is the guide portion 46 . The end of the guide portion 46 in the Z1 direction is open to the through portion 45 . The end of the guide portion 46 in the Z2 direction opens to the third surface 4c of the fixing portion 424 facing in the Z2 direction. This guide portion 46 is used when fitting the pin 5 into the through portion 45 . The width of the guide portion 46 increases with increasing distance from the through portion 45 . The width direction of the guide portion 46 is a direction perpendicular to the axial direction of the through portion 45 and the extending direction of the guide portion 46 . That is, the width of the guide portion 46 is the distance between the two inner peripheral surfaces 460 in the X direction. If the width of the end of the guide portion 46 in the Z direction is wide, the pin 5 can be easily fitted into the guide portion 46 . Unlike this example, the width of the guide portion 46 may be uniform in the extending direction of the guide portion 46, that is, in the Z direction.

A width W2 of the guide portion 46 is narrower than a width W1 of the through portion 45 . The width W2 is the width of the portion of the guide portion 46 connected to the through portion 45 . The width W1 is the maximum length of the opening of the through portion 45 in the width direction of the guide portion 46, that is, in the X direction. The width W2 is narrower than the maximum width W3 of the shaft portions 51 and 52 in the width direction of the guide portion 46 . The maximum width W3 is the length between the X2-direction outer end of the shaft portion 51 that is not elastically deformed and the X1-direction outer end of the shaft portion 52 that is not elastically deformed. The width W3 is the same as or slightly smaller than the width W1. The width W3 may be slightly larger than the width W1. Moreover, the width W2 is also a size through which the shaft portions 51 and 52 elastically deformed in the direction of approaching each other can pass. That is, the width W2 is larger than the distance between the X2-direction outer end of the elastically deformed shaft portion 51 and the X1-direction outer end of the elastically deformed shaft portion 52 . Therefore, the shaft portions 51 and 52 of the pin 5 guided by the guide portion 46 can reach the through portion 45 . Further, the pin 5 fitted in the through portion 45 is difficult to come off toward the guide portion 46 side.

[Busbar installation procedure]
A procedure for mounting the bus bar 4 will be described with reference to FIG. First, the busbar 4 is brought close to the pin 5 from the Z1 direction of the pin 5, and the shaft portions 51 and 52 of the pin 5 are fitted into the guide portions 46 of the busbar 4. As shown in FIG. Furthermore, the bus bar 4 is moved in the Z2 direction. As the pin 5 approaches the penetrating portion 45, the shaft portion 51 and the shaft portion 52 elastically deform toward each other. When the shaft portions 51 and 52 pass through the guide portion 46 , the distance between the shaft portions 51 and 52 increases, and the shaft portions 51 and 52 are fitted into the through portion 45 . Since the width W2 of the guide portion 46 is narrower than the width of the pin 5, it is difficult for the pin 5 to come off in the Z2 direction. When the shaft portions 51 and 52 are fitted into the through portion 45, the first portion 41 of the busbar 4 is pressed against the winding end portion 21 as shown in FIGS.

Next, the first portion 41 of the busbar 4 and the winding end portion 21 are joined by welding or the like. At this time, the three-dimensional movement of the bus bar 4 is regulated by the pin 5 . Since the position of the first portion 41 is less likely to shift with respect to the winding end portion 21, the first portion 41 and the winding end portion 21 can be easily joined.

≪Installation procedure of the reactor structure≫
The reactor structure α in FIG. 1 is, for example, screwed to an installation target. Installation targets include, for example, a converter case for housing a converter. A connection terminal of an external device is attached to the reactor structure α screwed to the installation target. Here, when the connection terminal is screwed to the terminal block 61, torque is generated to rotate the bus bar 4 around the screw shaft. In the configuration of this example, since the pin 5 restricts the movement of the busbar 4 , the application of excessive torque to the connecting portion between the first portion 41 and the winding end portion 21 is suppressed.

<<Effects of Embodiment 1>>
In the reactor structure α of this example, screws for fixing the busbar 4 to the reactor 1 are not required. Thus, the reactor structure α does not require a screw for fixing the busbar 4, and does not require the work of attaching the screw. Therefore, the reactor structure α of this example is excellent in productivity.

In the reactor structure α of this example, vibration of the bus bar 4 in the X, Y and Z directions is suppressed. Therefore, the stress caused by the vibration of the bus bar 4 is less likely to act on the connecting portion between the first portion 41 and the winding end portion 21 . Therefore, even if the intermediate portion of the bus bar 4 is not screwed as in the prior art, the reliability of the connecting portion is ensured.

<Embodiment 2>
A reactor structure α of Embodiment 2 will be described with reference to FIG. The busbar 4 of this example does not have the guide portion 46 . That is, the through portion 45 of this example is a through hole. The configuration is the same as that of the first embodiment except that the through portion 45 is a through hole.

In the configuration of the second embodiment, the busbar 4 is attached to the pin 5 from the Y1 direction side. The head portions 55 and 56 are sized to pass through the through portion 45 when the distance between the shaft portions 51 and 52 is reduced. When the heads 55 and 56 pass through the through portion 45, the distance between the shaft portions 51 and 52 increases, and the heads 55 and 56 are caught on the second surface 4b. The configuration of this example also determines the three-dimensional position of the busbar 4 with respect to the reactor 1 and restricts the three-dimensional movement of the busbar 4 with respect to the reactor 1 .

<Embodiment 3>
In Embodiment 3, a reactor structure α in which the axial direction of the pin 5 coincides with the Z direction will be described with reference to FIG. 8 . Only the busbar 4 is illustrated in FIG. The configuration of the third embodiment is the same as that of the first embodiment except for the axial direction of the pin 5 and the shape of the bus bar 4 . Therefore, in this example, only the differences from the first embodiment will be described.

In the busbar 4 of this example, the intermediate portion 422 is provided with the through portion 45 and the guide portion 46 . The guide portion 46 is not essential. In this example, the pin 5 (see FIG. 7) fitted in the through portion 45 extends in the Z1 direction. The pin 5 is provided, for example, on the XY plane of the pedestal 60 in FIG. The configuration of this example also provides the same effects as those of the first embodiment.

An intermediate portion 422 of the busbar 4 of this example is provided with a projecting portion 426 . The projecting portion 426 is provided on the opposite side of the penetrating portion 45 and the guide portion 46 in the width direction of the intermediate portion 422 . The projecting portion 426 is for securing the conductor cross-sectional area of the intermediate portion 422 .

<Embodiment 4>
In the fourth embodiment, a reactor structure α in which the axial direction of the pin 5 coincides with the X direction will be described with reference to FIG. 9 . Only the busbar 4 is illustrated in FIG. In this example, only differences from the first embodiment will be described.

In the busbar 4 of this example, a fixing portion 424 is provided at the end portion of the terminal portion 423 in the X2 direction. The fixed portion 424 is provided with a through portion 45 and a guide portion 46 . The guide portion 46 is not essential. In this example, the pin 5 (see FIG. 7) fitted in the through portion 45 extends in the X2 direction. The pin 5 is provided, for example, on the surface facing the X2 direction of the terminal block 61 in FIG. The configuration of this example also provides the same effects as those of the first embodiment.

<Embodiment 5>
≪Converter / power converter≫
The reactor structure α according to the embodiment can be used for applications that satisfy the following energization conditions. Current conditions include, for example, a maximum DC current of approximately 100 A to 1000 A, an average voltage of approximately 100 V to 1000 V, and a working frequency of approximately 5 kHz to 100 kHz. The reactor structure α according to the embodiment can be typically used as a component of a converter installed in a vehicle such as an electric vehicle or a hybrid vehicle, or as a component of a power conversion device including this converter.

A vehicle 1200 such as a hybrid vehicle or an electric vehicle is driven by a main battery 1210, a power conversion device 1100 connected to the main battery 1210, and power supplied from the main battery 1210 as shown in FIG. and a motor 1220 that Motor 1220 is typically a three-phase AC motor, drives wheels 1250 during running, and functions as a generator during regeneration. In the case of a hybrid vehicle, vehicle 1200 includes engine 1300 in addition to motor 1220 . In FIG. 10, an inlet is shown as the charging point of vehicle 1200, but a plug may be provided.

The power conversion device 1100 has a converter 1110 connected to a main battery 1210 and an inverter 1120 connected to the converter 1110 for mutual conversion between direct current and alternating current. Converter 1110 shown in this example boosts the input voltage of main battery 1210 from approximately 200 V to 300 V to approximately 400 V to 700 V and supplies power to inverter 1120 when vehicle 1200 is running. During regeneration, converter 1110 steps down the input voltage output from motor 1220 via inverter 1120 to a DC voltage suitable for main battery 1210 to charge main battery 1210 . The input voltage is a DC voltage. Inverter 1120 converts the direct current boosted by converter 1110 into a predetermined alternating current and supplies power to motor 1220 when vehicle 1200 is running, and converts the alternating current output from motor 1220 into direct current during regeneration and outputs the direct current to converter 1110. are doing.

The converter 1110 includes a plurality of switching elements 1111, a drive circuit 1112 that controls the operation of the switching elements 1111, and a reactor structure 1115 as shown in FIG. 11, and converts the input voltage by repeating ON/OFF. . Conversion of the input voltage means stepping up and down in this case. A power device such as a field effect transistor or an insulated gate bipolar transistor is used for the switching element 1111 . The reactor structure 1115 has a function of smoothing the change when the current increases or decreases due to the switching operation by using the property of the coil that prevents the change of the current to flow in the circuit. As the reactor structure 1115, the reactor structure α according to any one of the first to fourth embodiments is provided. Power conversion device 1100 and converter 1110 are excellent in productivity by including reactor structure α and the like, which are excellent in productivity.

In addition to converter 1110, vehicle 1200 is connected to power feed device converter 1150 connected to main battery 1210, sub-battery 1230 serving as a power source for auxiliary equipment 1240, and main battery 1210 to supply the high voltage of main battery 1210. An accessory power supply converter 1160 for converting to low voltage is provided. Converter 1110 typically performs DC-DC conversion, but power supply device converter 1150 and auxiliary power supply converter 1160 perform AC-DC conversion. Some power supply converters 1150 perform DC-DC conversion. The reactor structure 1115 of the power supply device converter 1150 and the auxiliary power converter 1160 has the same configuration as the reactor structure α of any one of the first to fourth embodiments, and the size, shape, etc. are appropriately changed. You can use a reactor structure with Further, the reactor structure α of any one of Embodiments 1 to 4 can also be used for a converter that converts input power and that only boosts or only steps down.

α Reactor structure 1 Reactor 10 Braid 2 Coil 20 Winding part 21, 22 Winding end part 3 Core 3A, 3B Split core 31 Inner core part 32 Outer core part 4 Bus bar 4a First surface, 4b Second surface 4c third surface 41 first portion 42 second portion 42h terminal hole 421 connecting portion 422 intermediate portion 423 terminal portion 424 fixing portion 425 notch 426 projecting portion 45 through portion 450 inner peripheral surface 46 guide portion , 460 inner peripheral surface 5 pin 51, 52 shaft portion 55, 56 head portion 55P, 56P projecting portion 510, 520 outer peripheral surface 511, 521 inner peripheral surface 6 resin molded member 6a first surface, 6b second surface 60 Pedestal Part 61 Terminal Block 61h Screw Hole 9 Insulating Members W1, W2, W3 Width 1100 Power Conversion Device 1110 Converter 1111 Switching Element 1112 Drive Circuit 1115 Reactor Structure 1120 Inverter 1150 Power Supply Device Converter 1160 Auxiliary Machine Power Supply converter 1200 vehicle 1210 main battery 1220 motor 1230 sub-battery 1240 auxiliaries 1250 wheels 1300 engine

The converter of the present disclosure is
A reactor structure of the present disclosure is provided.

The power conversion device of the present disclosure is
A converter of the present disclosure is provided.

The reactor structure of the present disclosure, the converter of the present disclosure, and the power converter of the present disclosure are excellent in productivity.

In the configuration of form <3>, the pin is likely to be caught in the portion of the penetrating portion that is connected to the guide portion. Therefore, the bus bar is less likely to come off in the direction opposite to the sliding direction at the time of attachment.

The converter includes the reactor structure of the embodiment with excellent productivity. Therefore, the above converter is excellent in productivity.

The power conversion device includes the converter of the embodiment with excellent productivity. Therefore, the power converter is excellent in productivity.

[Penetration part]
The through portion 45 penetrates through the fixed portion 424 in the thickness direction. That is, the penetrating portion 45 opens to the first surface 4 a and the second surface 4 b of the fixed portion 424 . That is, the axial direction of the penetrating portion 45 coincides with the plate thickness direction of the fixed portion 424 . The contour shape of the opening of the penetrating portion 45 is not particularly limited. As shown in FIG. 6, the contour shape of the opening of the penetrating portion 45 of this example is a quadrangle with rounded corners, with one side missing. Unlike this example, the contour shape of the opening of the through portion 45 may be an ellipse or a perfect circle with a part missing.

The shaft portions 51 and 52 of the pin are fitted into the through portion 45 . The outer peripheral surface 510 of the shaft portion 51 and the outer peripheral surface 520 of the shaft portion 52 are in contact with or close to the inner peripheral surface 450 of the through portion 45 . Proximity in this specification means that the gap between the outer peripheral surfaces 510 and 520 of the shaft portions 51 and 52 and the inner peripheral surface 450 of the penetrating portion 45 is 1 mm or less. The gap may be, for example, 0.7 mm or less, or 0.5 mm or less. The gap is preferably as small as possible in terms of manufacturing.

Claims (10)

a reactor having a coil and a core;
a bus bar for electrically connecting the coil and an external device,
The reactor is
having a pin made of a resin material,
The busbar is
a plate-shaped first portion connected to the winding end portion of the coil in an overlapping state;
A plate-shaped second portion extending from the first portion,
The second part is
a first surface facing the reactor;
a second surface opposite the first surface;
a penetrating portion penetrating from the first surface to the second surface;
The pin is
a plurality of shaft portions divided in a direction orthogonal to the axial direction of the pin and arranged inside the through portion;
a head formed at the tip of each shaft and arranged outside the penetrating portion;
each shaft faces the inner peripheral surface of the through portion so as to restrict movement of the bus bar in a direction perpendicular to the axial direction of the pin;
each head faces the second surface so as to restrict movement of the busbar in the axial direction of the pin;
Reactor structure. The second portion includes a notch-shaped guide portion connected to the through portion,
2. The reactor structure according to claim 1, wherein said plurality of shaft portions are two shaft portions divided in the width direction of said guide portion. 3. The reactor structure according to claim 2, wherein a width of a portion of said guide portion connected to said through portion is narrower than a maximum length of an opening of said through portion in a width direction of said guide portion. 4. The reactor structure according to claim 2, wherein the width of said guide portion increases with increasing distance from said through portion. The reactor structure according to any one of claims 1 to 4, wherein the through portion is provided in the second portion at a position closer to the first portion side. an X direction in which the winding end portion and the first portion are arranged in parallel;
a Y direction that intersects the X direction and is along the extending direction of the winding ends;
The reactor structure according to any one of claims 1 to 5, wherein the axial direction of the pin extends along the Y direction. The reactor includes an insulating member that determines the relative position of the coil and the core,
7. The reactor structure according to any one of claims 1 to 6, wherein said pin is provided on said insulating member. 8. The reactor structure according to claim 7, wherein said insulating member is a resin molded member that integrates said coil and said core. Equipped with the reactor structure according to any one of claims 1 to 8,
converter. comprising a converter according to claim 9,
Power converter.

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